Building and swimming pool construction

ABSTRACT

The specification describes a building panel with a snap engaging fitting for simplified interlocking of multiple panels to form building structures. The panels are especially suitable for swimming pool construction with a convenient crib-type arrangement that can be easily and quickly assembled.

United States Patent Boassy et al.

[54] BUILDING AND SWIMMING POOL CONSTRUCTION [72] Inventors: Emil J.Boassy, Berkeley Heights; Vincent Shanni, Scotch Plains, both of NJ.

[73] Assignee: Champion Incorporated, Scotch Plains,

[22] Filed: July 21, 1970 [21] Appl.No.: 56,802

[52] US. Cl ..52/169, 4/172.l9, 52/618 [51] Int. Cl ..E04h 3/16 [58]Field of Search ..52/495, 169, 627, 630, 618,

[5 6] References Cited UNITED STATES PATENTS 8/1966 Daly ..52/588 7/1969l-leirich ..52/627 [451 July 4,1972

3 ,427 ,663 2/1969 O'Connell ..52/ l 69 3,216,538 11/1965 Miller..52/495 3,253,371 5/1966 Honold ..52/627 3,419,917 1/1969 Schankler......52/l69 3,505,771 4/ 1970 Thompson ..52/495 FOREIGN PATENTS ORAPPLICATIONS 656,748 3/1965 Belgium ..52/495 France ..52/169 PrimaryExaminer-Henry C. Sutherland Attorney-Peter V. D. Wilde [57] ABSTRACTThe specification describes a building panel with a snap engagingfitting for simplified interlocking of multiple panels to form buildingstructures. The panels are especially suitable for swimming poolconstruction with a convenient crib-type arrangement that can be easilyand quickly assembled.

7 Claims, 4 Drawing Figures PATENTEDJUH I972 3.573 751 SHEET 30F 3 FIG.3

BUILDING AND SWIMMING POOL CONSTRUCTION This invention relates toconstruction panels for fabricating building units. More specifically itconcerns swimming pool structures made with these units.

Recent interest in modular building has created a demand for newbuilding panels. Panels which interlock with one another or with asimple frame are especially attractive.

This invention is directed in its broader aspects to such a panel.Installation of several panels to form a wall or other building unit canbe accomplished with a minimum of effort and expense.

The use of these construction panels in building swimming pools isespecially attractive. The inventive designs which incorporate thesepanels allow a nonskilled worker to complete essentially an entire poolconstruction in a surprisingly brief period.

This approach to swimming pool construction is essentially new. Currentmanufacturing methods favor unitary structures such as poured concreteor, in less expensive construction, simply a plastic liner set in acarefully sculptured sand excavation.

The construction panel of the invention is a dual thickness or rigid orsemirigid sheet material, suitable for building walls, with a structuralseparator in between. A filler in combination with the separator forincreased strength or rigidity or for thermal or acoustic insulation isoptional. The inventive feature of the panel is a snap fitting madeintegral with the rest of the panel and extending along at least oneedge thereof. The fitting comprises the edge portions of the sheetswhich are folded toward each other so as to essentially overlap. Achannel is formed along the edge of each sheet, and each channel isadapted to engage a retaining ridge in the female member. At least oneof the said edge portions is resilient so as to allow the channels tosqueeze together with pressure appropriately aplied. The interlockingparts may include sloped regions on the engaging surfaces to facilitatesnap fitting of the parts together.

The swimming pool according to the invention is made with a cribstructure. A frame including female fitting members is provided and thepanels are laid into the frame as slats in a crib. The panels eitherinterlock with one another or, preferably, are fitted into frame membersprovided between each panel. In many cases it will be convenient toemploy panels having lengths less than the overall pool dimension inwhich case two or more panels can be laid end to end and fitted onlyalong the sides of the panels. The ends of the panels engaging the cribframe can simply rest in the frame or can interlock in some fashion withthe frame. The sidewalls of the pool are constructed in a like manner bysimply snapping together a series of panels. The comer fittings aresomewhat more complex as will become evident later.

The panel structure is fabricated in a plastic-lined excavation, thelatter serving simply to retain water. This feature is especiallyimportant. The excavation requires a minimum of preparation since theliner need not be smooth. This means that a relatively thick plasticliner can be used without the common problem of avoiding wrinkles in theliner. It also means that puncture or tearing of the liner due to itsthinness or to pool trafiic is avoided. It is significant to note thatthe liner in this structure is not exposed to UV solar radiation. Thepanel assembly is inherently porous so that it remains submerged withinthe lined excavation. It is preferably supported from a frame on theground at the upper periphery of the excavation. However, since thepanels are typically relatively rigid, the weight of traffic on the poolbottom will be distributed and the use of the earth at the bottom of theexcavation for support in whole or part will not ordinarily beobjectionable.

These and other aspects of the invention will become apparent from thefollowing detailed description.

In the drawing:

P16. 1 is a sectional view of an exemplary construction panel accordingto the invention;

FIG. 2 is a perspective view of a swimming pool fabricated withconstruction panels similar to that of FIG. 1;

FIG. 3 is a sectional view through the end wall of the pool; and

FIG. 4 is a sectional view through the sidewall of the pool.

A building panel according to the invention is shown in FIG. 1. Itcomprises a top sheet 10 which is ordinarily square or rectangular indimension and terminates at both edges in a reentrant channel 11 and afolded edge portion 12. This leaves an interior channel portion 13. Thebottom sheet 16 is provided in this particular structure with largeridges or corrugations 17 for imparting longitudinal strength. Theremaining portion of the bottom sheet is glued or otherwise affixed tothe filler 18. The top sheet is likewise fastened to the filler 18. Thefiller can comprise a series of rib members spaced apart or could be anyof a number of structural members of a variety of materials simplyserving to support the top and bottom sheets in a spaced relationship.Foamed plastics such as polyurethane can be used in combination withrigid plastic, wood or metal supports.

The top sheet is shown flat for normal wall facings. However,corrugations, embossings and other designs may be used for decorativeand even functional purposes.

The bottom sheet 16 terminates at each edge with a V- shaped channel 19,a resulting V-channel 20 and a folded edge 21, the latter largelyco-extensive with the edge 12 of the top sheet. The terminal rim 22 onthis folded edge is optional in this design and simply serves as abearing when the edge is urged against the top sheet in interior channel13. Provided at the base of the V-channel 19 on the side thereof remotefrom the edge is a notch 23. This notch serves to engage the femalefitting as will be described.

This panel member is adapted to be used with joining strips, one ofwhich is shown at 30 engaging the right side of the panel. This fittingresembles an I-bar with one channel-forming member 31 somewhat longerthan the other channel forming member 32, although this feature is notper se essential. The edge fitting of the panel is adapted to engagewithin the channel 33 formed by arms 31 and 32 and main beam member 34.The arm 31 terminates with lip 35 which engages the.

notch 23 of the male fitting. Arm 32 terminates with lip 36 whichengages the re-entrant channel 11 of the panel. The lbar 30 ispreferably rigid.

It can be inferred from this drawing that the combination of the malefitting of the panel and the I-bar joining strip comprise aninterlocking assembly that can be joined simply by snapping the memberstogether, it being remembered that the edge portions of the panel aresufficiently resilient to allow the channels 11 and 20 to closetogether. The normal channel separation is such as to tightly engage thearms 31 and 32. The biased surfaces 37 and 38 in this particular designease the joining operation. The additional length of arm 31 as comparedwith the length of arm 32 also contributes to this result. This panel ismost effectively joined by tilting the top panel (or the joining strip)and engaging lip 36 and channel 11 first. Then by urging the membersinto horizontal alignment, the interlock is effected. The actualoperation is accomplished with remarkable ease and the interlockingjoint is very effective.

It will be evident that the V-groove 20 formed due to the presence ofthe adjacent corrugation is not vital to the structure. It is necessaryonly that a ridge extend along the edge of the panel beyond the normalpanel thickness.

The panel shown in FIG. 1 is provided with two male edge fittings to beused preferably with joining strips. However, one edge of the panel canbe provided with a female fitting resembling the l-bar 30 so thatmultiple panels can be assembled together directly. Further along theselines the l-bar joining strip can be permanently affixed to one edge ofthe panel during manufacture. One edge fitting can thus be eliminatedduring assembly.

In an exemplary embodiment the panel of FIG. 1 was constructed with 40mil sheets, a sheet separation of approximately 1 inch and an overallthickness of 3 inches. The overall panel size was approximately 4 X 8feet when joined. The corrugations 17 were on 3 inch centers. The filler18 was a continuous cross member with 1-86 inch corrugations made normalto the corrugations 17. All material was polystyrene or ABS. The edgefittings comprised a A inch deep by V4 inch channel in the top sheetwith a 1 inch folded edge. The channel 13 was 3/8" deep by approximately7/16 inch. The bottom sheet edge comprised in sequence a V4 inch rim, afolded edge approximately three-fourths inch, a 45 bend extendingapproximately 1 inch, a /4 inch notch, and an overall width ofapproximately l-% inch.

The joining strip 30 has an overall height of 2 inches, a width for arm31 of 3 inches, a width for arm 32 of l-% inch, a gauge generally ofone-eighth inch with 3/16 inch rims on arm 32, and /16 inch rims on arm31. The dimensions of this element were controlled very conveniently asthe strips were extruded PVC.

A swimming pool fabricated with construction panels of the type justdescribed is shown in FIGS. 2,3, and 4. FIG. 2 is a perspective view ofa pool showing the basic employment of the construction panels of FIG. 1in a crib-type structure.

At the top periphery of the pool is a decorative coping 40 made insections of a convenient length, e.g., 8 feet. Comer sections 41 includea 45 end for proper fitting. The side walls of the pool 42 compriseconstruction panels such as those described in connection with FIG. 1.Again the size of these panels is a matter of design choice. In thestructure shown, the side wall panels are approximately 4 X 4 feet.These panels are supported along their top edge with a fitting engaginga hanging grid. The hanging grid appears in subsequent figures. Thevertical edges of the panels simply butt together although a moldingstrip may be provided at this joint. The lower edges of the side wallpanels are provided with a floor support bracket which includes alaterally extending lip similar to a right-angle 7 bar. A portion ofthis floor support bracket shows at 43.

The end walls 44 are suspended at their upper edge in the same mannerbut engage a different floor support member, part of which appears at45.

The floor panels 46 are similar to the side and end wall panels and inthe structure shown are approximately 4 X 8 in size. The long edge ofthe panels include fittings which engage either the end wall floorsupport members 45 by joining strips 47.

The details of the hanging grid and the end wall floor support member 45can be seen in FIG. 3 which is a section through the end wall of. FIG.2. This figure also shows the disposition of the pool liner. The hanginggrid assembly comprises a flat support 50 which is laid flat over theearth or a prepared foundation and overhangs the excavation as shown.This support may be wood, aluminum, plastic or any suitable rigidmaterial. It conveniently comprises a peripheral walkway for the pool.Attached to the overhanging edge of the support 50 is a hanging bracket51. In the structure shown, this bracket serves four functions. The mostimportant involves the channel 52 and depending arms 53 and 54. Thesewill be identified as comprising the female fitting on one half of thejoining strip 30 shown in FIG. 1. The side wall and end wall panelsengage this fitting along their upper edge. Shown in FIG. 2 is a portionof an end wall panel 44.

The hanging bracket includes a U-shaped groove 69 into which the top ofthe pool liner 70 is fitted. The pool liner is a water-tight plasticmaterial similar to conventionally used liners except, as pointed outpreviously, it can be of heavier construction. For example, nylonreinforced vinyl having a thickness of 20 mils is suitable. It isunlikely that this material will be punctured or torn duringinstallation or use. Since the liner is not exposed to the suns rays, UVdegradation will be absent and it will only be necessary to protect theplastic against thermal oxidation, although this too will be minimal.

The hanging bracket 51 is also provided with a groove 68 for suspendingan earth retaining member 58. The earth retainer may be of heavy gaugeplastic, treated wood, or rustresistant metal. It preferably dependsbelow the midpoint of the depth of the excavation. In some cases wherethe sides of the excavation have exceptional integrity or whereauxiliary earth bonding procedures are employed, the retainer may beunnecessary.

However experience has shown that the typical earth excavation requiresthis, or a similar, provision for retaining the earth walls. It will beappreciated that this pool construction afiords considerable flexibilityin this regard since the pool liner 70 is outside the actual poolsurface. Thus the earth retaining members can assume a variety of formswith no thought to preserving a smooth surface for liner 70. Ifnecessary the retaining members can extend to the bottom of theexcavation and be supported with stakes into the bottom or the sides ofthe excavation.

Finally the hanging bracket 51 includes grooves 59 and 60 for attachingthe pool coping 40 as shown. Any convenient means for attachment wouldbe appropriate. Note that the coping covers the upper edge fitting ofthe panel 44 giving an attractive and integrated appearance to theassembly.

Afiixed to the lower edge fitting of panel 44 is the end wall floorjoining member 45. This joining member is similar to the joining strip30 except that the female channel fittings are disposed normal to oneanother. Thus arms 71 and 72 will be identified with arms 31 and 32 inFIG. 1. Likewise the lips 75 and 76 correspond in design and function tolips 35 and 36 of FIG. 1. A distinguishing feature is that one of thearms 72 has been omitted. This feature is helpful'since the floor panel46 cannot be manipulated to engage both the connecting beam 45 and thejoining strip 62 if the latter is already in place. The connecting beamis designed to permit the panel to be laid in place onto the lower arm71 and engaging the lip 75. This design is recommended for at least oneend (or side) of the pool. It will be evident that the beam at the otherend may have two standard female fittings molded in one piece as long asconstruction proceeds from that end. The fitting is completed from theinside of the pool by snapping the closure strip 77 into place. Theclosure strip is a right angle edge molding as shown with an anchorstrip 78 depending along the bisecting plane into engagement with theend wall-to-floor joining beam 45. The anchor strip includes a groove 79which engages a bead 80 provided along the central region of beam 45. Aclosure strip retaining member 81 provides a snap action fitting for theanchor strip. Since the member 45 is preferably formed of plastic orlight-weight metal, the retaining member 81 is partly resilient to allowfor the snap action fitting. The floor panel 46 engages the floorjoining beam 45 at lip 55 and lip 82 of the closure strip 77. Along theopposite side the panel engages the floor panel joining strip 62. Aportion of another floor panel is shown engaging the other fitting ofthe joining strip. Panels are joined in this manner until the desireddimension is reached. In the other dimension the panels simply buttend-to-end.

The floor-to-side wall joint is shown in detail in FIG. 4. The lowerportion of the sidewall panel is shown at 42. The sidewall-to-floorconnecting beam 43 is affixed to the lower edge fitting of panel 42. Theside walls and end walls may comprise more than one panel interlockedvertically depending upon the panel dimensions and the depth of thepool. In this case a joining strip such as that shown at 30 in FIG. 1 isused to join the panels in the same way the floor panels are joined.

The sidewall-to-floor connecting beam 43 resembles the end wall-to-floorbeam 45 in the portion engaging the sidewall 42. As the floor panelalong this edge does not have an interlocking fitting, the beam isprovided with a laterally extending portion 64 upon which the floorpanel rests. A short rounded stub 65 retains the upper surface of thefloor panel 46 and also provides an edge molding for the wall-to-fioorjoint. Holes 66 may be provided for an optional anchoring pin 67. Inthis view the filler member 18, appearing also in FIG. 1, is shown incross-section. 1

For simplicity, the pool illustrated has a uniform depth.

tional deep portion at one end of the pool are straightforward and hencewill not be detailed. Briefly, one such suucture would include floorpanel joining strips such as those shown at 30 in FIG. 1 in which thetwo female fittings, rather than being back-toback in the same plane,would be molded at an appropriate angle to pitch the bottom as desired.The lower edge of the side wall panels would be cut with an appropriatebias and the sidewall-to-floor connecting beam would be suitably bent orjointed.

The floor of the pool is shown suspended from the side and end walls butmay have additional support from the ground beneath the floor. This maybe especially useful during constructionyWith the pool filled, theweight supported by the floor will be inconsequential.

It is preferable that the panels be completely water permeable. It isessential to allow for flow of water through the assembled panelstructure.

Various additional modifications and deviations of these basicstructures will occur to those skilled in the art. All such variationswhich rely on the teachings through which this invention has advancedthe art are properly considered within the scope of this invention.

What is claimed is:

1. A swimming pool comprising a ground excavation, a hanging gridassembly disposed around the upper periphery of the excavation, saidhanging grid including means for attaching a pool liner to said hanginggrid, a flexible watertight pool liner attached to said hanging grid soas to cover the interior surface of the excavation, the hanging gridfurther including a pair of arms depending downwardly into theexcavation, the arms terminating in lip portions each extendinghorizontally towards the other arm to form a female fitting extendingaround the upper periphery of the excavation, a plurality of wallconstruction panels each having a male fitting along the upper and loweredge thereof, the male fitting on the upper edge engaging the femalefitting of the hanging grid to form side and end walls, the malefittings having retaining ridges extending along the upper and loweredge of the panel for engaging the lip portions of the hanging grid, atleast a portion of the panel being compliable so that the upper andlower ridges can be squeezed together while engaging the hanging grid, afloor beam extending around the lower periphery of the excavation,saidfloor beam comprising, along two opposite sides of the lower periphery,a plurality of wall-to-floor joining members, each joining member havingtwo female fittings disposed at a right angle, the fittings each havingtwo parallel arms terminating with lip portions facing approximatelytogether for engaging the retaining ridges of a male fitting with one ofsaid female fittings engaging the male fitting of a wall constructionpanel, a plurality of floor construction panels each having malefittings similar to the wall construction panels joined together withfemale joining strips to form a pool floor assembly, the pool floorassembly having, along two opposite sides thereof, male fittingsengaging a female fitting of the wall-to-floor joining member.

2. A swimming pool comprising a ground excavation, a hanging gridassembly disposed around the upper periphery of the excavation, saidhanging grid including means for attaching a pool liner to said hanginggrid, a flexible, watertight pool liner attached to said hanging grid soas to cover the interior surface of the excavation, and a crib-type,water-permeable interior pool shell attached to said hanging grid andextending into the covered excavation, said interior pool shellcomprising a plurality of side wall and end wall construction panelsdepending from the hanging grid and interlocked with snap fittings toform pool side and end walls, and a plurality of floor constructionpanels interlocked with snap fittings to form a pool floor, the poolfloor being attached to the side wall and end wall panels.

3. The swimming pool of claim 2 further including a floor retaining beamattached to the panels along two opposite walls of the pool andcomprising an L shaped member, one leg of said L interlocked with thewall panels and the other leg of the L sup p grtingthe floorconstruction panels.

4. e swrmmmg pool of claim 2 further including snap fittings on thehanging grid for attaching a pool coping to the hanging grid byinterlocking with the snap fittings.

' 5. A construction panel comprising a top sheet, a bottom sheetsubstantially coextensive with the top sheet and spaced therefrom, afiller body filling the space between said sheets to which each sheet isafiixed, a peripheral region of said top sheet extending beyond thefiller body, said region being resilient and having an edge portionfolded toward the bottom sheet and a re-entrant channel formed paralleland adjacent to said folded edge portion, the said region having anapproximately S-shaped transverse cross-section, a peripheral region ofsaid bottom sheet coextensive with said peripheral region of the topsheet, said region of said bottom sheet being resilient and having anedge portion folded toward the top sheet and being contiguous to theinside of the folded edge portion of said top sheet, the edge of saidedge portion being spaced from the top sheet so as to allow movement ofthe top peripheral region with respect to the bottom peripheral region,and a V- shaped channel adjacent to and extending parallel to the foldededge portion, said channel having a notch at the base of the V on theside thereof remote from the edge.

6. The panel of claim 3 in which the top and bottom sheets comprisepolyvinylchloride.

7. The panel of claim 3 in which the filler body is a corrugated plasticmaterial and the top and bottom sheets are bonded thereto.

1. A swimming pool comprising a ground excavation, a hanging gridassembly disposed around the upper periphery of the excavation, saidhanging grid including means for attaching a pool liner to said hanginggrid, a flexible watertight pool liner attached to said hanging grid soas to cover the interior surface of the excavation, the hanging gridfurther including a pair of arms depending downwardly into theexcavation, the arms terminating in lip portions each extendinghorizontally towards the other arm to form a female fitting extendingaround the upper periphery of the excavation, a plurality of wallconstruction panels each having a male fitting along the upper and loweredge thereof, the male fitting on the upper edge engaging the femalefitting of the hanging grid to form side and end walls, the malefittings having retaining ridges extending along the upper and loweredge of the panel for engaging the lip portions of the hanging grid, atleast a portion of the panel being compliable so that the upper andlower ridges can be squeezed together while engaging the hanging grid, afloor beam extending around the lower periphery of the excavation,saidfloor beam comprising, along two opposite sides of the lower periphery,a plurality of wall-to-floor joining members, each joining member havingtwo female fittings disposed at a right angle, the fittings each havingtwo parallel arms terminating with lip portions facing approximatelytogether for engaging the retaining ridges of a male fitting with one ofsaid female fittings engaging the male fitting of a wall constructionpanel, a plurality of floor construction panels each having malefittings similar to the wall construction panels joined together withfemale joining strips to form a pool floor assembly, the pool floorassembly having, along two opposite sides thereof, male fittingsengaging a female fitting of the wall-to-floor joining member.
 2. Aswimming pool comprising a ground excavation, a hanging grid assemblydisposed around the upper periphery of the excavation, said hanging gridincluding means for attaching a pool liner to said hanging grid, aflexible, watertight pool liner attached to said hanging grid so as tocover the interior surface of the excavation, and a crib-type,water-permeable interior pool shell attached to said hanging grid andextending into the covered excavation, said interior pool shellcomprising a plurality of side wall and end wall construction panelsdepending from the hanging grid and interlocked with snap fittings toform pool side and end walls, and a plurality of floor constructionpanels interlocked with snap fittings to form a pool floor, the poolfloor being attached to the side wall and end wall panels.
 3. Theswimming pool of claim 2 further including a floor retaining beamattached to the panels along two opposite walls of the pool andcomprising an L shaped member, one leg of said L interlocked with thewall panels and the other leg of the L supporting the floor constructionpanels.
 4. The swimming pool of claim 2 further including snap fittingson the hanging grid for attaching a pool coping to the hanging grid byinterlocking with the snap fittings.
 5. A construction panel comprisinga top sheet, a bottom sheet substantially coextensive with the top sheetand spaced therefrom, a filler body filling the space between saidsheets to which each sheet is affixed, a peripheral region of said topsheet extending beyond the filler body, said region being resilient andhaving an edge portion folded toward the bottom sheet and a re-entrantchannel formed parallel and adjacent to said folded edge portion, thesaid region having an approximately S-shaped transverse cross-section, aperipheral region of said bottom sheet coextensive with said peripheralregion of the top sheet, said region of said bottom sheet beingresilient and having an edge portion folded toward the top sheet andbeing contiguous to the inside of the folded edge portion of said topsheet, the edge of said edge portion being spaced from the top sheet soas to allow movement of the top peripheral region with respect to thebottom peripheral region, and a V-shaped channel adjacent to andextending parallel to the folded edge portion, said channel having anotch at the base of the V on the side thereof remote from the edge. 6.The panel of claim 3 in which the top and bottom sheets comprisepolyvinylchloride.
 7. The panel of claim 3 in which the filler body is acorrugated plastic material and the top and bottom sheets are bondedthereto.